Daga Cell zuwa Module: Tsarin Samar da Modules na Back-Contact (BC) Solar

Gabatarwa: Me yasa Fasahar Baya-Baya Ke Sake Siffata Masana'antar Hasken Rana

Masana'antar PV tana tsakiyar canjin fasaha na gaske. PERC ya yi mulki na shekaru, TOPCon ya tashi da sauri, kuma yanzu gine-gine na uku yana jan hankalin masana'anta da masu haɓaka ayyuka: Fasahar sel ta Baya-Baya (BC).

Sel na gaba-gaba na al'ada suna ɓata ɓangaren hasken rana saboda layukan grid na ƙarfe suna kan gefen haske. Sel BC suna motsa kowace lamba ta lantarki zuwa baya. Gaba yana tsabta sosai. Wannan yana nufin mafi girman gajeriyar kewayawa, kyan gani, da ingancin kayayyaki wanda yanzu yana fafatawa kai tsaye da na yau da kullun.

Ga ɓangaren da ke sa BC ta zama mai ban sha'awa ga duk wanda ke gudanar da layin: samun daga tantanin BC da aka gama zuwa cikakken kayan BC ba aiki ɗaya ba ne da masana'antar ta yi shekaru da yawa. Babu busbars na gaba, babu yatsu na gaba. Wannan gaskiya ɗaya tana canza yadda ake haɗa sel, yadda ake gina igiyoyi, yadda ake tsara ribbons, da yadda kuke saita girke-girken lamination ɗinku.

Wannan blog ɗin yana tafiya ta cikin cikakken tsari daga tantanin BC zuwa kayan BC, mataki-mataki, tare da kayan aikin da ke ciki da kuma tarkon tsari da kuke buƙatar kula da su.

1. Fahimtar Tantanin BC: Taƙaitaccen Bayani

1.1 Menene Tantanin Tuntuɓar Baya?

Tantanin Tuntuɓar Baya (BC), wani lokaci ana kiransa Interdigitated Back Contact (IBC) ko kuma duk-tuntuɓar-baya, yana sanya duka tuntuɓar emitter da base a gefen baya na wafer a cikin tsari mai haɗaka. Gaba yana da siliki mara komai, wanda ke kashe abubuwa uku a lokaci ɗaya:

• Asarar inuwa, yawanci 3-5% na yankin tantanin akan sel na al'ada

• Asarar juriya da ke da alaƙa da cinikin ƙirar grid na gaba

• Visible gridlines, which matter a lot for looks

Manyan bambance-bambancen BC a 2024-2025:

Hanyar a bayyane take: BC yana motsawa daga samfur mai daraja na musamman zuwa mai fafatawa na yau da kullun, wanda masu yin China ke matsawa sosai ta hanyar 2024-2025.

1.2 Babban Bambanci: Geometry na Tuntuɓar

A kan kwayar PERC ko TOPCon, busbars na gaba (9-16 akan kwayoyin zamani) da yatsu ana kiyaye su sirara yayin da har yanzu suna tattara wutar lantarki. Kuna siyar da ribbon kai tsaye akan waɗannan busbars. Mai sauki.

A kan kwayar BC, gefen baya yana ɗauke da madaidaitan ratsi na nau'in n da p tuntuɓar a cikin tsari mai layi daya da haɗe-haɗe. Faɗi, tazara da tazarar waɗannan ratsi sun bambanta ga kowane mai yin, kuma suna da mallaka. Sun kuma yanke shawarar yadda za a haɗa kwayar a cikin wani module.

2. Tsarin Samar da Module na BC: Mataki-bi-Mataki

Layin module na BC yana raba kayan aiki da yawa tare da layin al'ada, kamar laminators, stringers da tashoshi na framing. Amma matakan haɗin kai da samar da string sun bambanta da gaske. Ga cikakken tsari:

Yanzu bari mu ɗauki kowane mataki bi da bi.

Mataki 1: Dubawa da Rarraba Cell mai shigowa

Cells na BC suna fitowa daga masana'antar cell a matsayin quadrants, cikakken girman ko rabin yanke, dangane da ƙirar module. Matakin farko ya dace da kowane layin module:

• Dubawa na gani don microcracks, chipping, gurɓata ko bambancin launi

• Gwajin I-V don Voc, Isc, Pmax da fill factor

• Hoton Electroluminescence (EL) don kama microcracks, karyewar yatsu, shunting ko wuraren da suka mutu

• Rarraba cell da binning ta hanyar ajin wutar lantarki, yawanci 1-2.5W bins, kuma ga cells na BC kuma ta hanyar daidaiton launi, tunda gaban mara rufi yana sa duk wani canjin launi ya bayyana sosai

Kalubale na musamman na BC: ba tare da ƙarfe na gaba ba, daidaiton launi shine komai, musamman ga mazaunin gida da BIPV inda kyan gani ke tafiyar da siyarwa. Yawancin masu yin BC suna amfani da ƙunshin launi mafi tsauri, wani lokaci ana tsara su ta musamman tare da masu karanta Lab* dabi'u, idan aka kwatanta da na'urori na al'ada.

Mataki na 2: Haɗa Cell / Haɗin Juna - Zuciyar Kera Module BC

Anan ne modules BC suka rabu sosai daga na al'ada, kuma inda yawancin sabbin kayan aiki suka zo.

2.1 Kalubalen Haɗin Juna

A kan cell na al'ada kuna siyar da ribbon lebur a kan busbars na gaba kuma ku ninka shi zuwa bayan cell na gaba. Sauƙin geometry.

A kan cell BC duka madaidaitan da marasa madaidaitan suna zaune a baya a cikin tsari mai haɗaɗɗiya. Don haka:

• Ribbon mai sauƙi na gaba-baya ba zai yi aiki ba

• Haɗin juna dole ne ya haɗa madaidaitan madauri na baya na cells maƙwabta

• Tazarar madauri, faɗi da daidaitawa suna na musamman ga mai kera

• Rashin daidaitawa yayin haɗawa yana haifar da asarar juriya ta jerin ko shunting

Hanyoyin haɗin kai guda biyu ne suka mamaye samar da yawa a yau.

Zabi A: Haɗin Manne Mai Gudanarwa (CA)

Wanda masu ƙirƙira kamar Aiko Solar suka goyi bayan ABC modules ɗinsu, wannan yana amfani da manne mai gudanarwa na lantarki (ECA), epoxy mai cike da azurfa, maimakon solder.

Tsari:

1. Na'urar rarraba daidai tana shimfida adadin manne mai gudanarwa a kan madaidaitan lambobin baya

2. Ana sanya mai haɗin kai, ribbon tagulla mai lebur ko kuma bugu mai sassauƙa (FPC), a kan mannen

3. Tarin yana warkewa a cikin tanda mai ƙarancin zafi, kusan 150-180C na minti 1-3, ko kuma a lokacin lamination

Fa'idodi:

• Sarrafa ƙarancin zafi, don haka ƙarancin damuwa na thermal akan sel, wanda ke da mahimmanci yayin da wafers ke tafiya zuwa 130 microns da ƙasa

• Babu lamba da ƙarfe na soldering, don haka ƙarancin microcracks

• Ƙarfin fine-pitch har zuwa sub-millimeter, daidai da tsarin interdigitated mai kyau

• Mannen da ya warke yana ɗan sassauƙa kuma yana ɗaukar damuwa na thermal-cycling fiye da solder mai tauri

Rashin amfani:

• ECA mai cike da azurfa yana da tsada

• Curing yana ƙara lokacin zagaye, kodayake curing na layi yayin lamination yana taimakawa

• Doguwar lokaci amincin haɗin ECA har yanzu ana tabbatarwa a babban sikeli, kodayake bayanan gwajin sauri na farko sun yi kyau

Zabi B: Zero-Busbar (0BB) Solder / Smart Wire Technology

Hanyar da ta fi dacewa, wadda masana'antun kamar LONGi ke amfani da ita don kayayyakin HPBC, galibi tare da low-temperature solder ko hanyoyin SmartWire.

Tsari:

1. Wayoyi masu sirara sosai, kusan 0.2-0.35mm, ko waya mai lebur (SmartWire) an riga an saita su a cikin firam ɗin ɗaukar hoto

2. Kwayar BC tana fuskantar sama, baya a bayyane, akan haɗin waya

3. Thermode (hot bar) ko infrared heating na ɗan lokaci yana sake narkar da solder akan waya don haɗa shi da ɗigon baya

4. Wayan yana tafiya zuwa kwayar gaba

Babban ra'ayin shine 0BB, zero busbar. Maimakon soldering ribbon mai kauri a kan busbars daban-daban, dozin na wayoyi masu sirara suna taɓa yatsun hannu na baya kai tsaye, don haka ba a buƙatar busbar mai kauri.

Fa'idodi:

• Yana gina kan kayan aikin solder da ake da su, don haka ƙananan capex

• Haɗin solder an fahimta sosai, don haka amincin yana da ƙarfi

• Wayoyin 0BB suna bin tsarin interdigitated

Rashin amfani:

• Yana buƙatar ingantaccen sarrafa zafin jiki, zafi mai yawa yana cutar da siraran wafers

• Daidaitawar waya zuwa lamba tana da matsi kuma tana da mahimmanci

• Dan kadan mafi girma jerin juriya fiye da CA a wasu saitunan

Kayan aikin Stringing: Sabon Zamani

Tun daga 2026-2027, manyan masu samar da BC stringing sun haɗa da:

Gudun haɗa BC cells yana kusan 10-15% a hankali fiye da cells na yau da kullun saboda matsananciyar daidaitawa, amma masu samarwa suna rufe wannan tazarar da sauri.

Mataki na 3: Tsarin String da Samuwar Matrix

Da zarar an samar da strings na BC, yawanci cells 2xN don shimfidar rabin yanke, suna shiga matrix na module:

• Gilashi ɗaya (gilashi/backsheet) ko gilashi biyu (gilashi/gilashi), na ƙarshe ya zama ruwan dare ga BC da ke nufin babban aminci da BIPV

• Ana sanya strings a kan encapsulant na baya a daidai tsarin jerin

• Tazarar string ta biyo girman module, misali module mai cell 72 na tushen M10 yana kaiwa kusan 2278 x 1134 mm

La'akari na musamman na BC: Cells na BC suna tura ɗan ƙaramin wutar lantarki, godiya ga rashin inuwa a gaba, kuma ba su da busbars na gaba a matsayin alamar gani. Don haka tsari yawanci yana ƙara duban gani don tabbatar da polarity cell kafin lamination. Yin kuskuren gane cell BC da aka juyar da shi yana da sauƙi fiye da cell mai lamba ta gaba tare da busbars bayyanannu.

Mataki na 4: Bussing da Solder Cross-Connector

Bayan shimfidawa, manyan ribbons na bas suna haɗa strings a jere don ƙara wutar lantarki.

Ga nau'ikan BC:

• Haɗa ribbon na bas yana bin ƙa'ida ɗaya da na'urori na yau da kullun, ribbon ana yi masa soldering a kan pads na busbar a gefen cell.

• Cells na BC sau da yawa suna ɗauke da pads na busbar na musamman a gefuna, waɗanda suka fi yatsu masu haɗe-haɗe na interdigitated fadi, don haka soldering na bas ya kasance mai sauƙi tare da kayan aiki na yau da kullun.

• Wasu ƙirar BC suna amfani da masu haɗa string da aka haɗe yayin stringing, wanda zai iya cire matakin bussing na daban.

Sabon salo, shingled + BC hybrid: wasu masu kera suna gwada shingled BC, suna yanka cells na BC zuwa ɓangarori kuma suna rufe su, don haka ba a buƙatar ribbon na bas na daban. Adhesive mai ɗaukar wuta a kowane rufewa yana yin haɗin jere. Har yanzu niche ne a 2025, amma yana da alƙawarin shimfidawa mai yawan ƙarfi.

Mataki na 5: Lay-Up (Encapsulant + Glass + Backsheet/Glass Assembly)

Lay-up yana kama da na'urar module na yau da kullun.

Ga module na BC na glass/backsheet:

1. Takardar encapsulant ta baya, EVA ko POE, 0.45-0.5mm, tana kan teburin lay-up.

2. Ana sanya igiyoyin BC/matrix a kai

3. Takin gaba na encapsulant yana rufe kan sel

4. Gilashin gaba, mai tauri da AR-coated don ingantaccen watsawa, yana kan saman

Don gilashin/gilashin BC module, wanda ya zama sananne:

1. Gilashin gaba, encapsulant na gaba, matrix cell, encapsulant na baya, gilashin baya (m don samun bifacial ko mara haske)

Bayanan kula na encapsulant na BC:

• POE (Polyolefin Elastomer) an fi so fiye da EVA don BC saboda ƙarancin watsa ruwa, wanda ke kare lambobin baya daga lalacewar danshi; mafi kyawun juriya na PID, wanda ke da mahimmanci lokacin da dukkan tsarin lantarki ke zaune a baya; da kuma mannewa mai ƙarfi ga saman baya mai santsi da aka yi da ƙarfe

• Daidaituwar kauri na encapsulant yana da mahimmanci a nan, saboda rashin daidaituwa na kwarara yana haifar da bambance-bambancen gani a gaba, gefen nunin BC module. Encapsulant mara daidaituwa na iya barin kumfa ko lahani na alamar ruwa da ke fitowa a gaba mara busbar

Mataki 6: Lamination

Tarin yana shiga cikin laminator, wanda shine mafi mahimmancin inji a kowane layin module.

Bayanan lamination na yau da kullun don BC modules:

Jimlar lokacin zagayowar: 25-40 mintuna dangane da encapsulant da laminator.

Kalubalen lamination na musamman na BC:

1. Kama iska a tuntuɓar baya. Tsarin yatsa mai haɗe-haɗe yana haifar da micro-topography wanda ke kama iska yayin lamination. Manyan masana'antun suna amfani da fina-finan encapsulant masu rubutu ko micro-channeled, wani lokaci ana kiran su venting encapsulant, don iska ta fita cikin sauƙi yayin matakan vacuum.

2. Curing conductive adhesive. If stringing used CA, lamination pulls double duty, encapsulating the module and curing the adhesive at the same time. The profile has to get the adhesive to full cure, roughly 150C for 10-plus minutes, without cooking the encapsulant.

3. Gudanar da bow cell. BC cells, musamman na bakin ciki a 140 microns ko ƙasa, na iya yin bow kaɗan daga damuwar asymmetric na rear metallization. Lamination dole ne ya ɗauki wannan bow ba tare da canza tazarar cell-to-cell ba, don haka ana daidaita viscosity na encapsulant yayin gelation a hankali.

Kayan laminator don BC modules. Irƙira manyan samfuran suna aiki duka ga layukan al'ada da BC, amma laminators da aka daidaita don BC suna kawo ingantaccen vacuum (dual-stage zuwa <0.5 mbar), daidaitaccen zafin jiki (kusan ±1.5C a kan tebur), da kuma shirye-shiryen matsa lamba na diaphragm, soft-press zuwa full-press.

Mataki 7: Gyara, Tsaftace Gefen, da Framing

Bayan lamination module yana samun:

1. Gyaran gefe, cire abin rufewa da ya wuce gefen gilashin

2. Nika gefe/dinke don aminci da kuma yanke wuraren damuwa

3. Haɗa firam tare da silicone sealant ko crimping na inji

Firam na musamman na BC. Modulolin BC galibi suna zama a matsayin samfuran manyan farashi don rufin gida, BIPV da kasuwanci masu daraja, don haka kamannin firam suna da mahimmanci. Firam ɗin baƙi, anodized ko fenti, suna daidai don kiyaye kamannin baƙi. Wasu modulolin BC suna tafiya ba tare da firam ba tare da sealant na gefe kawai, musamman don BIPV. Tsarin firam na iya zama sirara ko amfani da haɗin kusurwa mai tsabta don dacewa da kamannin tantanin halitta mai santsi.

Mataki na 8: Shigar da Akwatin Junction

Akwatin junction yana hawa a baya kuma yana haɗuwa da bus ribbons.

Don modulolin BC, akwatunan J masu ƙaramin profile da ƙarancin tashi an fi so, sake don kamanni da dacewa da BIPV. Wasu masana'antun suna amfani da ƙirar akwatin J da aka haɗa tare da bypass diodes da aka saka a cikin modul maimakon a cikin akwatin waje. Yin soldering ko crimping na jagororin akwatin J zuwa wutsiyar bus ribbon daidai yake da na modulolin al'ada, amma jagororin ya kamata su nisanta daga saman baya mai yawan lamba don hana kowane gajeren kewayi.

Mataki na 9: Curing da Sanyaya

Bayan firam da J-box:

• Curing silicone: mintuna 15-30 a zafin daki, ko kuma cikin sauri a cikin bututun iska mai dumi a 60-80C na mintuna 5-10

• Yanayin zafi: wasu masana'anta suna gudanar da tsararren module ta hanyar bututun sanyaya mai sarrafawa don daidaita encapsulant da rage damuwa kafin gwajin lantarki

Mataki na 10: Gwajin Flash da Hoto na Electroluminescence (EL)

Ƙofar inganci ta ƙarshe kafin tattarawa.

Gwajin flash (I-V curve). Na'urar kwaikwayo ta hasken rana, yawanci ajin AAA+ bisa ga IEC 60904-9, tana harba haske mai daidaitacce (AM1.5G, 1000 W/m2, 25C) kuma tana karanta cikakken I-V curve: Pmax, Voc, Isc, FF da ingancin yankin module.

Modules na BC suna kaiwa akai-akai:

• Ingancin module 22.5-24.0% don nau'ikan 182mm ko 210mm na yau da kullun

• 580-620W don daidaitaccen module mai rabin-cell 72-cell ta amfani da sel M10

Hoto na Electroluminescence (EL). Ana shigar da wutar lantarki a ƙarƙashin matsi na gaba kuma kyamarar infrared tana ɗaukar haske. Wurare masu duhu suna nuna ƙananan tsagewa, karyewar yatsu ko madaurin tuntuɓar, shunting, ko matattun sel.

Bayanan EL na musamman na BC. Ana harba EL don na'urorin BC daga baya, inda tuntuɓar da hanyoyin wutar lantarki suke. Hotunan sun bambanta da EL na gaba-sel, tsarin yatsu masu haɗe-haɗe yana bayyana a sarari kuma lahani suna kama daban. Masu aiki da tsarin EL na tushen AI suna buƙatar ɗakunan karatu na lahani na musamman na BC.

Mataki 11: Binciken gani, Lakabi, da Tattarawa

Matakai na ƙarshe:

• Binciken gani don lahani na ado, karce a gilashin gaba, lahani a firam, zubar da man shafawa

• Lakabi da bayanan wutar lantarki, takaddun shaida (IEC 61215, IEC 61730, MCS, UL da sauransu), lambar serial, kwanan watan kera

• Tattarawa, yawanci 30-36 na'urori a kowace pallet, tare da masu kare kusurwa, ɗaure da nannade

Saboda na'urorin BC suna kan ƙarshen farashi mai girma, matakan inganci galibi suna hawa: wasu masana'antun suna gudanar da binciken EL 100% maimakon samfur, ƙa'idodin ado suna ƙara tsauri (babu lahani a bayyane a cikin yankin aiki), kuma tattarawa na iya ƙara kayan alama ko jagororin masu shigarwa don masu sauraron gida.

3. Mahimman Abubuwan Da Ake La'akari Da Su Game da Inganci da Dogaro na BC Modules

4. Matsayin Masana'antar Samfura na BC a 2026-2027

Kasuwar samfura na BC tana haɓaka da sauri:

• LONGi ta shiga cikin BC (HPBC 2.0) a matsayin fasahar gaba ta yau da kullun, tare da iyawar da aka sanar ta fiye da 50 GW a ƙarshen 2025

• Aiko Solar ta haɓaka ABC zuwa ma'aunin multi-GW, tare da ingancin tantanin halitta na samarwa sama da 25.5%

• Tongwei, JinkoSolar da Risen Energy duk suna haɓaka TBC (TOPCon-BC hybrid) ko nau'ikan BC zalla don samarwa na 2025-2026

• Maxeon tana ci gaba da yin samfuran IBC masu inganci a masana'antunta na Malaysia da Mexico

• Masu samar da kayan aiki kamar Autowell, SC Solar da Leadmicro sun ƙaddamar da tsarin stringers da layup na musamman na BC

Ingancin samfur yanzu ya kai 23.0-24.0% ga samfuran BC na kasuwanci (silicon mai haɗaɗɗiya guda ɗaya), tare da nau'ikan wutar lantarki sama da 600W a cikin sifofin daidaitattun.

Tazarar farashi tsakanin samfuran BC da TOPCon ta ragu zuwa kusan 0.05-0.10 yuan/Wp, ƙasa da $0.02/Wp, kuma masu nazari da yawa suna tsammanin BC zai kai daidaiton farashi da TOPCon nan da 2026-2027 yayin da amfani da kayan aiki ke haɓaka kuma azurfa a kowace watt ke ci gaba da raguwa.

5. Kammalawa: Samar da Module na BC - Fiye da Canjin Cell Kawai

Gina module na BC ba kawai saka cell na BC a cikin layin al'ada ba ne. Haɗin kai, zaɓin encapsulant, girke-girke na lamination, tsarin dubawa da matsayin inganci duk suna buƙatar amsoshi da aka tsara musamman waɗanda suka mutunta geometry da ƙimar cell na back-contact.

Kyakkyawan: kayan aiki, kayan aiki da ilimin tsari suna girma cikin sauri. Abin da ya yi hidima ga kasuwar zama mai daraja kawai shekaru biyar da suka gabata yanzu yana kan iyakar karɓuwa na GW-scale.

Ga duk wanda ke auna hanyar BC, shawara mai sauƙi ce. Ka fara gyara matakin haɗin kai, inda kusan kashi 80% na aikin tsari yake. Ka sami stringing daidai, ka zaɓi encapsulant mai dacewa, sauran layin ya fi canji fiye da juyin juya hali.

Zamanin module na back-contact ya zo.

Ra'ayin Ooitech

Muna gaya wa abokan ciniki abu ɗaya koyaushe idan sun tambaya game da layin BC: duk wasan yana cikin stringer da encapsulant, ba sauran layin ba. Samun CA dispensing mai maimaitawa kuma zaɓi POE mai kyau, kuma layin module da aka gina da kyau yana ɗaukar geometry na rear-contact ba tare da damuwa ba. Abu ɗaya da ya canza a yi nuni, Ooitech yana ba da layin (assembly) module kawai, ba samar da cell ba, don haka aikin BC yana haɗa kayan aikinmu na layup, lamination da gwaji tare da kowane cell BC da kuka samo. Idan kuna son ganin wannan aiki a cikin masana'anta na gaske, tashar YouTube ta Ooitech a www.youtube.com/ooitech wuri ne mai kyau don kallon ainihin stringing da lamination footage.